Tooling system

A method of operating a tooling system to produce a desired smooth, curved surface contour, the tooling system having a plurality of elements arranged in an array, the elements of the array being movable between a closed position in which the elements contact one another and are secured in position, and an open position in which the elements of the array are spaced apart and are capable of vertical movement relative to one another, which method of operating includes at least the steps of:

• (i) firstly carrying out an opening step to move the elements of the array to the open position;
• (ii) secondly carrying out a first moving step to move the elements of the array into a first alignment that is different from an alignment that produces the desired surface contour;
• (iii) thirdly carrying out a first machining step to machine free ends of the elements according to a predetermined pattern;
• (iv) fourthly carrying out a second moving step to move the elements of the array into a second alignment;
• (v) fifthly carrying out a closing step to move the elements of the array into the closed position;
• (vi) sixthly carrying out a separating step to separate a first group of elements of the array from a second group of elements of the array along a vertical split line;
• (vii) seventhly carrying out a third moving step to move one of said first and second group of elements away from the other of said first and second group of elements in a horizontal plane;
• (viii) eighthly carrying out a second machining step to machine one or more elements of the array exposed by the third moving step, and
• (ix) ninthly carrying out a fourth moving step to move at least one of the first and second groups of elements such that the first and second groups are back into contact with one another, whereby the machined free ends of the elements produce the desired smooth, curved surface contour.